Carrier 58WAV Guide

INDUCED-COMBUSTION 58WAV & 58ZAV
GAS FURNACE
USER’S INFORMATION MANUAL FOR
THE OPERATION AND MAINTENANCE
OFYOUR NEW GAS-FIRED FURNACE
— Do not store or use gasoline or other flammable
vapors and liquids in the vicinity of this or any
other appliance.
— WHAT TO DO IFYOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use
any phone in your building.
• Immediately call your gas supplier from a
neighbor’s phone. Follow the gas supplier’s
instructions.
• If you cannot reach your gas supplier, call the
fire department.
— Installation and service must be performed by a
qualified installer, service agency or the gas
supplier.
WARNING: If the information in this manual
is not followed exactly, a fire or explosion may
result causing property damage, personal injury or
loss of life.
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NOTETO INSTALLER:
THIS MANUAL MUST BE LEFTWITHTHE
EQUIPMENT USER.
Do not use this furnace if any part has been under
water. Immediately call a qualified service techni-
ciantoinspectthefurnaceand to replaceanypart
of the control system and gas control which has
been under water.

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WELCOME TO TODAY’S
GENERATION OF
COMFORT
Congratulations!Your new, higher
efficiencygas furnaceis asound invest-
ment which will reward you and your
family with years of warm memories
winter after winter.
Not only is your new furnace energy
efficient, it is also extremely reliable.
Spend just a few minutes with this
booklet to learn about the operation
of your new furnace—and the small
amount of maintenance it takes to
keep it operating at peak efficiency.
Years went into the development of
your new furnace. Take a little time
now to assure its most efficient opera-
tion for years to come.
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MODEL 58WAV
UPFLOW FURNACE
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MODEL 58ZAV
DOWNFLOW/
HORIZONTAL FURNACE
UPFLOW FURNACE COMPONENTS
Relief Box
Rating Plate
Gas Valve Control Knob or Electric Switch (On/Off)
Gas Valve
Gas Burner
Flame Sensor
Air Filter Retainer
Air Filter
Blower and Blower Motor
Draft Safeguard Tube and Switch
Gas Manifold
Manual Reset Limit Switch
Hot Surface Ignitor
Blower Door Safety Switch
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DOWNFLOW/HORIZONTALFURNACE
COMPONENTS
Manual-Reset Auxiliary Limit Switch (when used)
Blower and Blower Motor
Relief Box
Gas Valve Control Knob or Electric Switch (On/Off)
Gas Valve
Gas Burner
Rating Plate
Blower Door Safety Switch
Draft Safeguard Tube and Switch
Gas Manifold
Manual Reset Limit Switch (2)
Hot Surface Ignitor
Flame Sensor
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IMPORTANT FACTS
Your furnace must have adequate airflow for efficient com-
bustion and safe ventilation. Do not enclose it in an airtight
room or “seal’’ it behind solid doors.
To minimize the possibility of serious personal injury, fire,
furnace damage, or improper operation;
carefully follow
these safety rules:
•Keep the area around your furnace free of combustible
materials, gasoline, and other flammable liquids and vapors.
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•Do not cover the furnace, store trash or debris near it, or
in any way block the flow of fresh air to the unit.
•Combustion air must be clean and uncontaminated with
chlorine or fluorine. These compounds are present in
many products around the home, such as: water softener
salts, laundry bleaches, detergents, adhesives, paints, var-
nishes, paint strippers, waxes, and plastics.
Make sure the combustion air for your furnace does not con-
tain any of these compounds. During remodeling be sure the
combustion air is fresh and uncontaminated. If these com-
pounds are burned in your furnace, the heat exchangers and
metal vent system may deteriorate.
•A furnace installed in an attic or other insulated space
must be kept free and clear of insulating material. Examine
the furnace area when installing the furnace or adding more
insulation. Some materials may be combustible.
NOTE: Do not use this furnace if any part has been under
water. Immediately call a qualified service technician to
inspect the furnace and to replace any part of the control
system and any gas control which has been under water.
NOTE: The qualified installer or agency must use only
factory-authorized replacement parts, kits, and accessories
when modifying this product.
This furnace contains safety devices which must be manu-
ally reset. If the furnace is left unattended for an extended
period of time, have it checked periodically for proper oper-
ation. This precaution will prevent problems associated
with no heat, such as frozen water pipes, etc. See “Before
You Request a Service Call’’ section in this manual.
SAFETY CONSIDERATIONS
Installing and servicing heating equipment can be hazard-
ous due to gas and electrical components. Only trained and
qualified personnel should install, repair, or service heating
equipment.
Untrained personnel can perform basic maintenance func-
tions such as cleaning and replacing air filters. All other
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operations must be performed by trained service person-
nel. Observe safety precautions in this manual, on tags, and
onlabelsattachedtothefurnace,andothersafetyprecautions
that may apply.
Recognize safety information. This is the safety-alert sym-
bol . When you see this symbol on the furnace and in
instructions or manuals, be alert to the potential for personal
injury.
Understand the signal words DANGER, WARNING, and
CAUTION. These words are used with the safety-alert sym-
bol. DANGER identifies the most serious hazards which
will result in severe personal injury or death. WARNING
signifies hazards which
could result in personal injury or
death. CAUTION is used to identify unsafe practices which
would result in minor personal injury or product and prop-
erty damage. NOTE is used to highlight suggestions which
will result in enhanced installation, reliability, or operation.
STARTING YOUR FURNACE
Instead of a continuously burning pilot flame, your furnace
uses an automatic hot surface ignition system to light the
burners each time the thermostat signals the furnace to start.
Follow these important safeguards:
•Never attempt to manually light the burners with a match
or other source of flame.
•Read and follow the operating instructions on the furnace,
especially the item that reads as follows:
Wait 5 minutes to clear out any gas. Then smell for gas,
includingnear the floor.Ifyou smellgas,
STOP! Follow“B’’
in the safety information above on this label. If you don’t
smell gas, go to the next step.
•If a suspected malfunction occurs with your gas control
system, such as the burners do not light when they should,
refer to the shutdown procedures on the furnace, or in the
next section, to turn off your system, then call your dealer as
soon as possible.
•
CheckAir Filter: Before attempting to start your furnace,
be sure the furnace filter is clean and in place. (See the main-
tenance section of this manual.) Then proceed as follows:
STEPS FOR STARTING YOUR
FURNACE
1. Set your room thermostat to the lowest temperature set-
ting. (See Fig. 7.)
2. Close the external manual gas valve. (See Fig. 8.)
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3. Turn OFF electrical supply to the furnace. (See Fig. 9.)
4. Remove the furnace access door(s).
a. Downflow/Horizontal—Remove blower door after
removing 2 screws first, then remove the control
door. (See Fig. 10.)
b. Upflow—Remove control door. (See Fig. 11
.)
10 11
5. The gas valve will have EITHER a control knob or con-
trol switch to turn off and on. Turn the control knob or
switch on the gas valve to the OFF position and wait
5 minutes. (See Fig. 12 or 13.)
6. After waiting 5 minutes, turn the control knob or switch
on the gas valve to the ON position. (See Fig. 14 or 15.)
7. Replace the access door(s). See Fig. 16 for upflow and
Fig. 17 for downflow. Replace control door first on
downflow furnaces. Then replace blower door (secure
with 2 screws).
WARNING
Should overheating occur or the gas valves fail to
shut off the gas supply, turn off the manual gas
valve (See Fig. 8.) to the furnace BEFORE turning
off the electrical supply. A failure to follow this
warning could result in a fire or explosion, and
personal injury or death.
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18 19
8. Turn ON the electrical supply to the furnace. (See
Fig. 18.)
9. Open the external manual gas valve. (See Fig. 19.)
10. Set the room thermostat to a temperature slightly
above the room temperature. This will automatically
signal the furnace to start. The inducer motor will start,
and the hot surface ignitor will energize. When hot, the
ignitor will have an orange glow.
11. After 15 to 70 sec, the gas valve permits gas to flow to
the main burners where it is ignited. Hot flames begin
to warm the furnace’s heat exchanger. After a time
delay of approximately 45 sec, the furnace blower is
switched on.
NOTE: If the main burners fail to ignite, the furnace control
system will go through 3 more ignition cycles. Then, if burn-
ers fail to ignite, the system will lockout. If lockout occurs,
ortheblowerdoesnotcomeon—shutdownyourfurnaceand
call your dealer for service.
12. Set your thermostat to the temperature that satisfies
your comfort requirements. SUGGESTION: Setting
the thermostat back a few degrees—and compensating
for the difference with warmer clothing—can make a big
difference in your fuel consumption on extremely cold
days. The few degrees at the top of your thermostat “com-
fort level’’ are the most costly degrees to obtain.
When the room temperature drops below the temperature
selected on the thermostat, the furnace will switch on auto-
matically. When the room temperature reaches the setting
selected on the thermostat, the furnace will be automatically
switched off.
Some thermostats have a “FAN’’ switch with 2 selections:
AUTOandON.WhenthermostatissetonAUTO,thefurnace
blower cyclesonand off,controlledby thethermostat. InON
position, the furnace blower runs continuously except for a
45-secdelayatthe“call forheat.’’Thiskeepsthetemperature
level in your home more evenly balanced. It also continuous-
ly filters the indoor air.
SHUTTING DOWN YOUR FURNACE
Should you ever suspect a malfunction in your furnace, you
will need to turn the furnace off. The following procedures
must be followed:
1. Set your room thermostat to the lowest temperature
setting. (See Fig. 20.)
2. Close the external manual gas valve (See Fig. 8 on
page 4.)
3. Turn OFF electrical power to your furnace. (See Fig. 21.)
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ON
OFF
OR
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OFF
OR
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16 17

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4. Remove the control access door on your furnace. (See
Fig. 10 or 11.) On upflow furnaces, removing the blower
access door is not required.
5. Turn the control knob or switch on the gas valve to the
OFF position. (See Fig. 22 or 23.)
6. Replace the control access door. (See Fig. 16 or 17.)
7. If the furnace is being shut down because of a malfunc-
tion, call your dealer as soon as possible.
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PERFORMING ROUTINE
MAINTENANCE
With proper maintenance and care, your furnace will operate
economically and dependably. Basic maintenance, which can
easilybeaccomplished by someonewho followsthe directions,
isfoundonthisand thefollowingpages.However, beforebegin-
ning maintenance, follow these safety precautions:
FILTERING OUT TROUBLE
A dirty filter will cause excessive stress on the furnace, heat
exchanger, and blower motor and can cause it to overheat
and automatically shut down. The furnace filter should be
checked every 3 or 4 weeks and cleaned if necessary.
If installed with factory specified disposable media filter,
check or replace filter before each heating and cooling sea-
son. Replace disposable media filter at least once a year.
If your furnace filter needs replacing, be sure to use the
same size and type of filter that was originally supplied. Use
the Furnace Filter Table and match your furnace size with
the proper filter size.
The air filter for upflow furnaces is normally located in the
blower compartment. (See Fig. 3) or in the factory-supplier
filter cabinet attached to the side or bottom of the blower cab-
inet. Filters for the downflow furnaces are normally located
inthereturn-airplenumabovetheblower.Ifairfilterhasbeen
installed in another location, contact your dealer for instruc-
tions. To inspect, clean and/or replace the air filter(s), follow
these steps:
•
Upflow Furnaces Only—
1. Turn off the electrical supply to the furnace. (See
Fig. 21.)
2. Remove door/access panel
•AIR FILTER(S) LOCATED IN BLOWER COM-
PARTMENT
Remove control and blower access doors. (See Fig. 10
and 11)
•AIR FILTER LOCATED IN FILTER CABINET
Remove filter cabinet door (See Fig. 30 and 31)
NOTE: It will be necessary to remove 1 thumbscrew.
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OFF
OR
WARNING
Turn off electrical power supply to your furnace
before removing the access doors to service or
perform maintenance. A failure to follow this
warning could result in personal injury or death.
CAUTION
Although special care has been taken to minimize
sharp edges, be extremely careful when handling
parts or reaching into the furnace.
CAUTION
Never operate your furnace without a filter in place.
Doing so may damage the furnace blower motor.
An accumulation of dust and lint on internal parts
of your furnace can cause a loss of efficiency.
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24 25
3. Remove air filter from furnace.
•AIR FILTER LOCATED IN BLOWER COMPART-
MENT:
a. Slide filter retainer sideways until it is free of latch.
(See Fig. 24)
b. Gently remove air filter and carefully turn the dirty
side up (if dirty) to avoid spilling dirt from the filter
(see Fig. 25)
•AIR FILTER LOCATED IN FILTER CABINET:
a. Re-install door.
b. Slide air filter out of furnace. Keep dirty side up (if
dirty) to avoid spilling dirt. (See Fig. 32 and 33)
4. Inspect the filter. If torn, replace it.
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NOTE: If washable filter that was shipped with the furnace
has been replaced with:
a) Factory specified disposable media filter –Do not clean.
If dirty, replace only with media filter having the same
part number and size. Install with airflow direction arrow
pointing towards blower.
b) Electronic air cleaner (EAC) –Refer to EAC owner’s
Manual for maintenance information.
5. Wash filter (if dirty) in sink, bathtub, or outside with a gar-
den hose. Always use cold tap water. A mild liquid deter-
gent may be used if necessary. Spray water through filter
in the opposite direction of airflow. Allow filter to dry.
6. Reinstall clean air filter
7. Reinstallfilterretainer(forblowercompartmentlocations
only)
8. Replace control and blower doors (See Fig. 16 and 17) or
filter cabinet door (Fig. 34 and 35)
9. Turn on electrical supply to furnace (see Fig 18).
NOTE: For upflow models only—ifside returnducts are used,
2 filters may be required in some models.The procedure listed
above may be used to remove side filters.
•
Downflow/Horizontal Furnaces Only:
Two filters are located in the return-air plenum above the
blower (above line-of-sight) resting in theV-shaped channel
on top of the furnace. (See Fig. 27.)
1. Turn off electrical supply to the furnace. (See Fig. 21.)
2. Remove 2 screws from blower access door and remove
the door.
3. Remove the left-side filter by tipping the filter toward
the center and raising it from theV-shaped channel in
which it rests. (See Fig. 27 and 28.)
4. Lower filter down along side of the blower and remove
from the furnace.
5. To remove the right-side filter, lift from V-shaped channel
and remove through left side the same way as left-side filter.
6. Inspect the filter. If torn, replace the filter.
7. Wash the filter (if dirty) in a sink, bathtub, or outside
with a garden hose.Always use cold tap water.A mild
liquid detergent may be used if necessary. Spray water
through the filter in opposite direction of airflow. Allow
filter to dry.
8. Reinstall the clean filters.
27 28
9. Replace blower door and secure with 2 screws. Turn
ON electrical supply to your furnace. (See Fig. 18.)
UPFLOW FURNACE AIR FILTERTABLE
AIR FILTER LOCATED IN BLOWER COMPARTMENT
FURNACE
CASING
WIDTH (IN.)
FILTER SIZE (IN) FILTER
TYPESide Return Bottom Return
14-3/16 (1) 16 x 25 x 1* (1) 14 x 25 x 1 Cleanable
17-1/2 (1) 16 x 25 x 1* (1) 16 x 25 x 1* Cleanable
21 (1) 16 x 25 x 1 (1) 20 x 25 x 1* Cleanable
24-1/2 (1 or 2) 16 x 25 x 1 (1) 24 x 25 x 1* Cleanable
AIR FILTER LOCATED IN FILTER CABINET
FILTER
CABINET
HEIGHT (IN) FILTER SIZE (IN) FILTER TYPE
16 (1) 16 x 25 x 1*
or (1) 16 x 25 x 4-5/16 Cleanable Disposable
20 (1) 20 x 25 x 1*
or (1) 20 x 25 x 4-5/16 Cleanable Disposable
24 (1) 24 x 25 x 1*
or (1) 24 x 25 x 4-5/16 Cleanable Disposable

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* Factory provided with the furnace. Filters may be field modified by cutting
filter material and support rods (3) in filters. Alternate sizes and additional
filters may be ordered from your dealer.
COMBUSTION AREA AND
VENT SYSTEM
Inspect the combustion area and vent system before each
heating season. An accumulation of dirt, soot, or rust can
mean a loss of efficiency and improper performance. Build-
upsonthemainburnerscancausefaultyfiring.This“delayed
ignition’’ is characterized by an alarmingly loud sound. If
your furnace makes a loud noise when the main burners are
ignited, shut down the furnace and call your servicing dealer.
Use your flashlight and follow these steps for inspecting the
combustion area and vent system of your furnace:
1. Turn off electrical supply to the furnace and remove
the access doors. (See Fig. 9, and 10 or 11.)
2. Carefully inspect the gas burner for dirt, rust, or scale
(see Fig. 29). Inspect the relief box, flue connection
area, and the vent pipe for rust.
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NOTE: If dirt,rust,soot, orscaleaccumulations arefound,call
your servicing dealer. DO NOT OPERATE THE FURNACE.
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DOWNFLOW/HORIZONTAL FURNACE FILTERTABLE
FURNACE CAS-
ING WIDTH (IN.) FILTER SIZE (IN) FILTER TYPE
14-3/16 (2) 16 x 20 x 1* Cleanable
17-1/2 (2) 16 x 20 x 1* Cleanable
21 (2) 16 x 20 x 1* Cleanable
24-1/2 (2) 16 x 20 x 1* Cleanable
CAUTION
Use care when cutting support rods in filters to
protect against flying pieces and sharp rod ends.
Wear safety glasses, gloves, and appropriate pro-
tective clothing. Failure to follow this caution
could result in personal injury.
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33
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3. Inspect the vent pipe for a sag, holes, or a disconnection.
A horizontal vent pipe must slope upward. If rusty joints
or seams, or signs of water leakages are found,
call your dealer for service.
4. Replace the access doors and restore electrical power
to the furnace. Be sure bottom door flange is inside of
the furnace casing. (See Fig. 16 and 17, and 26.)
5. Start the furnace and observe its operation. If possible,
watch the burner flames.Are they burning bright blue?
If not or if you suspect some other malfunction, call
your servicing dealer.
BEFORE YOU REQUEST A
“SERVICE CALL’’
Before you call for service, check for several
easily solved problems:
•Check for sufficient airflow. Check the air filter for dirt.
Check for blocked return-air or supply-air grilles. Be sure
they are open and unobstructed. If this isn’t the cause of the
problem, call your servicing dealer.
If your furnace isn’t operating at all, check the following list
for easily solved problems:
•Is your thermostat set above room temperature? Is the
HEAT mode selected?
•Is the electrical power supply switch on? Is the blower
access door firmly in place?Are any fuses blown? (There is a
fuse on the furnace control.) Has a circuit breaker tripped?
•Is the manual shut-off valve in the gas supply pipe leading
to the furnace open? Does the lever point in the same direction
that the pipe runs (open)? Or is it at a right angle to the pipe
(closed)?
NOTE: Before proceeding with the next checks, turn off the
electrical power supply to the furnace. Remove access doors.
•Is the control knob or switch on the gas valve turned to the
ON position? If this or the preceding check shows an interrup-
tion in the gas supply, make sure the gas has not been shut off
forsafetyreasons.If nothingelseseemsto bewrong,followthe
startup procedures found on pages 4 and 5 of this booklet.
•If for some reason the vent is blocked, the draft safeguard
switch will shut off the furnace. Reset the switch by pushing
the button located on top of the switch. (See page 2 or 3 for
switch location.)
If the switch trips a second time, turn off the furnace and call
for service.
•Downflow/Horizontal Only—Check the manual reset aux-
iliary limit switch (when used) located on the blower housing.
If the blower motor fails, this switch will shut off the furnace.
Reset it by pushing the button on the switch. If it trips again,
turn off the furnace and call for service.
•Check the manual reset limit switch(es) located near the
burners. If the furnace has experienced a high-temperature con-
dition due to inadequate combustion air, these switches will
shut off the furnace. Reset the switch(es) by pushing the button
on the switch. If the switch trips a second time, turn off the
furnace and call for service.
•If your furnace still fails to operate, call your servicing deal-
er for troubleshooting and repairs. Tell your dealer the model
and serial numbers for your furnace. (You should have them
recorded on page 8 of this booklet.) By knowing exactly which
furnace you have, the dealer may be able to offer suggestions
WARNING
If holes are found or if the vent pipe is obstructed
or is not connected, toxic fumes can escape into
your home. DO NOT OPERATE YOUR FURNACE.
Call your dealer for service. A failure to follow this
warning could result in personal injury or death.
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over the phone or save valuable time through knowledgeable
preparation for the service call.
Regular dealer maintenance
In addition to the type of routine maintenance you might be
willing to do, your furnace should be inspected regularly by a
properly trained service technician.A semiannual inspection
(or annual inspection, at least) should include the following:
1. Inspection of all flue product passages including the burn-
ers, heat exchanger, relief box, and vent pipe.
2. Inspection of all combustion and ventilation air
passages and openings.
3. Close check of all gas pipes leading to and inside of your
furnace.
4. Inspection, cleaning, and lubrication (when required) of
the blower motor and wheel.
NOTE: Refer to the unit Service Procedures for blower motor
oiling information.When required, the motor must be oiled by
a qualified service technician.
5. Routine inspection and cleaning/replacement of the air filter.
6. Inspection of all supply- and return-air ducts for obstruc-
tions, air leaks, and insulation.Any problems found should
be resolved at this time.
7. Inspectionof furnaceinstallationfor propersupport andany
obvious deterioration of the furnace. The support must be
sound and without sags, gaps, cracks, etc., around the fur-
nace base so as to provide an air seal between the support
and furnace.
8. A check for loose connections attaching individual compo-
nents.Inspectionofallelectrical wiringandtheir connections.
9. Operationalcheckofthefurnaceitselftodetermineworking
condition. Repair or adjustment should be made at this time.
Ask your servicing dealer for further details about an econom-
ical service contract that covers seasonal inspections.